Insulated building panel assembly



5 Sheets-Sheet l J. R. THYGESON, SR

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April 9, 1968 .1. R. THYGESON, SR 3,376,578

INSULATED BUILDING PANEL ASSEMBLY Filed Jan. lO, 1966 5 Sheets-Sheet 2 INVENTOR: BY JOHN R. THYGESONSR.

ATTYS R. THYGESON, SR 3,376,678

INSULATED BUILDING PANEL ASSEMBLY pnil 9, 1968 5 Sheets-Sheet 5 Filed Jan. lO, 1966 INVE NTOR: JOHN R,1HYGEsoN,sR.

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April 9, 1968 J. R. THYGESON. SR

INSULATED BUILDING PANEL ASSEMBLY Filed Jan. lO, 1966 5 Sheets-Sheet 4 F'IGQ.

JOHN R. THYGESON, SR.

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ATTYS l/a f4 J. R. THYGESON, SR

INSULATED BUILDING PANEL ASSEMBLY FIG. l2 555456 f/ 50g April 9, 196s Filed Jan. lO, 1966 INVENTOR'.

JOHN R. THYGEsoN, SR.

United States Patent 3,376,678 INSULATED BUILDING PANEL ASSEMBLY John R. Ihygesorn Sr., Fox Chase Manor, Pa., assignor to Proctor & Schwartz, Inc., Philadelphia, Pa., a corporation of Pennsylvania Filed lIan. 10, 1966, Ser. No. 519,607 10 Claims. (Cl. 52-204) ABSTRACT GF THE DISCLGSURE panels. An insulated door panel, having its hinge anchored within an adjacent panel slot, is perlpherally sealed when the door is closed.

The present invention relates to building construction, and has particular application to an improved panel assembly for use in erecting buildings or compartments which must be insulated from the surrounding atmosphere.

It is common practice to erect buildings and compartments from Prefabricated panel members which are assembled with similar panels at the building site. To provide the desired durability, the panel members comprise a block of insulation material having facing sheets or shells of metal or similar durable material which is normally inherently heat-conductive. The facing sheets or shells are interconnected by spacer elements which limit the heat conduction between the inner and outer facing elements of the panel. In assembling the panel members to one another, the panel members may be welded or otherwise permanently secured together to form the insulated compartment. In those installations where it is desired to avoid a Ipermanent interconnection of the panel members, for example where the compartment is expected to have a short life of use or where it must be changed in dimension periodically, the practice has been to fabricate the panels so as to interlock with one another. This has to be done by forming the opposite side edges of the panel member with complementary locking forms which interengage to form the completed structure. Alternatively, separate locking members extending along the length of the assembled wall have been provided to interconnect the panel members into a unitary structure. None of the prior methods of assembly have been entirely satisfactory because of diiiiculties in assembling and disassembling the panel members or because of the substantial cost lof the structure.

With the foregoing in mind, the present invention provides a panel assembly for use in erecting insulating compartments in which edge formation of the panel members is of uniform construction about their entire periphery and in which connectors span between and interconnect two adjacent panel members which may be disposed in side-wise-abutting and aligned relation.

The panel assembly of the present invention enables rapid erection of the assembly and at the same time affords easy disassembly of isolated panel members from the erected structure without disturbing other panel members, thereby aifording easy replacement of damaged members .or easy substitution of special-purpose panel members.

The panel assembly of the present invention also permits its use in extremely high-temperature operations .'ildi Patented Apr. 9, 1968 where the panel members are subject to expansion and contraction, since the assembly affords such expansion and contraction without buckling or otherwise damaging the structure.

The panel assembly of the present invention in addition to providing an insulated structure, provides a structure which is substantially airtight so as to insure against escape of gaseous medium from the interior of the compartment into the body of the panel members or through the erected structure; except in cases of explosion where explosion panels are provided to afford emergency escape of the gaseous medium, the air tightness enabling the elimination of interior ductwork, distribution boxes, and the like.

The panel assembly of the present invention provides a rigid and structurally sound unit capable of supporting the normal loads associated with insulated compartments without the necessity for additional reinforcing or supporting frameworks.

All of the objects of the present invention are more fully set forth hereinafter with reference to the accompanying drawings wherein:

FIG. 1 is a plan view with a portion removed .of a dryer housing embodying a panel assembly in accordance with the present invention;

FIG. 2 is a view in side elevation of the housing shown in FIG. 1;

FIG. 3 is a fragmentary end elevation of the structure shown in FIG. 2;

FIG. 4 is a fragmentary sectional View taken on the line 4 4- of FIG. 2;

FIG. 5 is a detached perspective view lof a panel member with portions broken away to more clearly illustrate its construction;

FIG. 6 is a sectional view taken on the line 6-6 of FIG. 5;

FIG. 7 is a sectional view taken on the line '7 7 of FIG. 2 showing a door construction in an assembly of the present invention;

FIG. t3 is a sectional view taken on the irregular section line 8 8 of FIG. 2;

FIG. 9 is a plan view of a corner member of the panel assembly shown in FIG. 8;

FIGS. 10 and 1l illustrate the form of the facing elements of the corner member shown in FIG. 9;

FIG. 12 is a fragmentary view similar to FIG. 4 showing a modified mounting arrangement for an explosion panel;

FIGS. 13 and 14 are sectional views taken on the lines 13-13 and 14-14 of FIG. 1; and

FIG. 15 is a sectional view taken on the line 15-15 of FIG. 13.

Referring now to the drawings, FIGS. 1 to 3 inclusive illustrate a typical compartment embodying a panel assembly made in accordance with the present invention, in the present instance a drying chamber. As shown, the cham-ber comprises side walls 12, end walls 13 having portals 14 for the admission and discharge of the material to be dried, and a roof structure 15. The material is fed through the dryer by conveyors (not shown) and is dried, preferably by heated air circulated by central blowers (not shown) having drive mechanisms 16 (see FIG. 2) mounted on the side Wall 12, and overhead exhaust ducts 20. Infiltration of fresh gaseous drying medium into the drying chamber is controlled by air lock exhausts comprising suitable ductwork, indicated generally at 17, and exhaust Iblower elements 18 mounted on the roof structure 15. Access doors 19 are provided in the side walls to permit entry of personnel into the chamber.

The chamber is erected with prefabricated panel members which are set in place and interconnected in a simple and expeditious manner. As best shown in FIG. 5, each panel member comprises inner and outer facing elements 31 and 32 respectively on opposite sides of the center plane of the panel member. The elements take the form of rectangular sheet-like body portions 33 having peripheral flanges 34 projecting substantially at right angles to the body portion 33 inwardly of the panel member and having at their inner edges turned-back lips 35. yPreferably, the material of the facing elements 31 and 32 is hard, durable sheet material having a degree of resilience, such, for example, as aluminized steel sheets. As best shown in FIG. 6, the reverse lip 35 converges outwardly toward the flange 34, the resilience of the material affording displacement of the lip into substantial parallelism with the flange 34, as shown in broken lines, so as to provide between the flanges 34 and the lip 35, a slot 36 for receiving a fastener or connector, as described more fully hereinafter.

The inner and outer facing elements 31 and 32 are interconnected in parallel relation by spacer elements 37 which span between and are secured to the spaced-apart flanges 34 of the elements 31 and 32. In the present inj stance, the spacer elements are welded to the flanges. The spacers 37 maintain the facing elements 31 and 32 in spaced relation to limit heat conduction therebetween. In the present instance, limited conduction may occur through the spacer 37, and if this limited conduction is unsatisfactory, the spacer 37 may be formed of a nonconductive material. To further limit heat transmission through the panel member, the space between the facing elements 31 and 32 is provided with insulation 38, preferably of a brous batt type. In addition, where the panels are of substantial length, reinforcing angle memn bers may lbe secured to the inner surface of the facing elements. As shown in FIG. 5, angle members 39 of right angle form `have one ange secured to the body portion 33 of the facing element and the other flange projecting inwardly at right angles thereto, the depth of the flange being less than the depth of the peripheral flange 34 so that when the opposite facing elements 31 and 32 are united, the opposed angle reinforcing members 39 do not provide a path for heat conduction through the panel member. It should be noted that the peripheral flanges 34 and lips 35 ofthe panel member are of identical cross section about the entire periphery so that the members may be connected with similar members side-to-side, end-toend, or even side-to-end.

At the corners of the structure, corner panel members 40 are provided (see FIGS. 8 to l1). The corner panel members 40 are similar to the panel members 30 comprising inner and outer facing elements 41 and 42 respecy tively. The panels are interconnected by spacer members 47 and have insulation 4S therebetween. The angular body portion 43 of the inner and outer face elements 41 and 42 have side flanges 44 with turned-back lips 45 cooperable with the flange 44 to provide a slot 46 identical to the Y slot 36 of the side panels 30. The inside element 41 is provided along its upper and lower edges with flanges 44a and lips 45a cooperating to form a slot similar to the slot 46; and the outer element 42 is provided at its upper and lower edges with flanges 44b and lips 45b, which likewise cooperate to form a slot similar to the slot 46 formed by the flanges 44 and lips 45.

The roof of the chamber is formed by similar panel members 50. As shown in FIG. 4, the roof panel members 50 comprises an outer facing element 51 and an inner facing element 52. Each of these elements has a peripheral flange 54 projecting inwardly therefrom and terminating in a reversely-turned lip 55 cooperating with the flange 54 to provide a slot 56. Insulation material 58 is positioned intermediate the facing elements 51 and 52 and a reinforcing angle 59 serves to reinforce the panel. In the roof panels 50, the reinforcing angle 59 has one flange secured to the outer facing element 51 and has its other flange extending toward the center plane of the panel. Such reinforcement is provided in areas where the roof panel must support a load. `In other respects, the roof panel members are identical to the side panel members.

In the assembly of the building structure, the side panels 30 are erected in edge-to-edge abutment about the periphery of the chamber to be erected. This is accomplished by anchoring a sill member 60, which consists of a U-shaped channel member having upstanding legs 61 and 62, on the foundation to conform to the outline of the chamber. The side and corner panels are then engaged between the upstanding legs of the anchoring sill member 60. The interior leg 62 of the sill member 60 has a sealing strip 63 disposed along its length so as to sealingly engage the inner facing element 32 of the panel members mounted therein. The panel members 30 are interconnected in edgewise abutting relation by means of` clips 65 which are U-shaped in cross section, as shown in FIG. 8 and extend continuously along the vertical extent of the abutting panels. The legs of the U-shaped clip 65 engage respectively in the slots 36 of the two ad-` joining panels, the clip being pushed into the slots so as to deflect each lip 35 away from the flange 34 to provide space for engagement of the leg therebetween. The resilience of the material comprising the flange 34 and lip` 35 insures a rm engagement of the clip 65, and the flanges, lips, and clips cooperate to provide a labyrinth seal against the passage of gaseous medium therethrough. When the chamber is pressurized, the pressure within the chamber operates on the clips to assist in retaining them in engagement with the slots. It should be noted that the clip when engaged in the slots 36 as shown in FIG. 8, does not project :beyond the surface of the body portion 33 of the facing element so that the entire assembly may be received between the legs 61 and 62 of the sill member at the lower edge of the panel members.

The clip is inserted into the slots vby engaging one end of the clip into the slots of the adjacent panel members at the associated end of the panel members, and then driving the clip into the slot whereby the legs of the clip serve to cam the lips 35 outwardly so as to open the slots 36 to receive the legs of the clips 65. The clips 65 are engaged in the slots 36 on both sides of the wall formed by the panel members 30l so as to form an extremely rigid and sturdy wall assembly. The corner panel members 41 are united to the wall assemblies in a similar manner by the use of the clips 65.

A wall embodying a panel assembly in accordance with the present invention, preferably employs panel members 30 of uniform size throughout. In accordance with the invention, when it is desired to replace or repair a damaged i panel member, or to replace a plain panel member with a panel member having special characteristics, such as one including windows or instrument panel mounts, the particular panel member may be removed from the assembly without substantially disturbing the remaining panel members of the wall assembly. The removal of the panel member is accomplished by removing the clips uniting the panel member with the adjacent panel members and then simply lifting the freed panel member from the sill. This is possible because ofthe avoidance of overlap between adjacent panel members which enables free displacement of the panel member in either direction perpendicular to the plane of the panel member.

In addition to providing easy removal and replacement of panel sections, the U-shaped'clips cooperating with the flanges and lips of the panels provide expansion joints along the length of the wall erected of the panel mem-` bers. In drying chambers where the chamber is subject to wide fluctuations in temperature, the thermal expansion and contraction of the panel members has a tendency to buckle walls of conventional construction. The clips and flanges of the present invention provide an effective bellows action permitting expansion and contraction of the walls without buckling and without losing the sealing action afforded by the joint.

In the area where an access door is desired, a conventional panel may be omitted and a door panel inserted in its place. As shown in FIG. 2, the door panel may consist of a door 19 having a width corresponding to the width of a panel 30, a sill 71, and a lintel member 72 below and above respectively the door 19. As shown in FIG. 7, the door is hinged to the panei 30a at one side of the door opening and is latched to the panel 30b at the other side of the door opening. The panels 30a and 30h are standard panel members. The door is supported by a piano hinge .73 which has one leaf 74 secured to the door structure 19 and its other leaf 75 secured, for example by fasteners 7`6a, to a support angle 76 engaged in the slot 36a formed by the fiange and lip of the panel 30a and anchored therein by suitable fasteners 77.

Door stop means 78 is provided about the interior of the door opening and is secured to the interior flanges 34 and lips 35. Suitable seals extend continuously about the door opening at 79 and 80 to make the door gas-tight. At

the other side of the door, a keeper 82 is mounted by means of an angle member 82h in the slot 36h of the panel member Bob to cooperate with a latch element 83 carried by a shaft 83a pivotally mounted in a bushing 84 extending through the door. A handle element S5 is mounted on the shaft 83a on the exterior of the door. The door 19 is constructed somewhat similarly to the panel members 30 consisting of an inner facing element 86, an outer facing element 87, intermediate insulation 88, and suitable spacer elements 89 interconnecting the inner and outer facing elements. In order to protect the interior insulation of the panel members 36a and 30h, cover strips 91 of tape or similar material bridge between the lips of the opposed facing elements of the panel.

It should be noted that the sealing arrangement of the door assembly is such that the sealing members '79 and are not subjected to scutiing as the door is opened and closed. To this end, the inner facing element is formed with a continuous inset wall 92 about its entire periphery and a reverse flange 93 projecting into the space provided by the inset wall. The door stop 7S and sealing member S0 is mounted on the latch side and top and bottom edges of the door opening to project into the space provided by the inset wall 92 so that, as the door swings closed, the fiange 93 effects compressive engagement with the seal 80 without scufhng. By the same token, the seal 79 at the hinge side edge of the door is mounted on the inner facing element to project into the space provided by the inset Wall so that as the door swings closed, the side of the ange 93 effects compressive engagement with the seal 79 without scuing.

The panel members of the present invention are of sufiicient structural rigidity to support the roof 15 without additional supporting framework. In drying chambers, it is frequently required to provide an explosion panel which is free to unseat in the event of explosion or conflagration within the dryer. With reference to FIG. 1, roof panel members 50a are fixedly mounted on the walls of the chamber and explosion roof panels 50b are mounted for upward displacement in the event of explosion.

' The roof panel members are mounted on the side walls by means of a T-shaped rail 95 mounted with the leg 96 of the T engaged in the slots formed between the flanges and the lips extending along the upper edge of the wall panel members. The cross piece 97 of the T-rail has its lower portion bearing against the inner surface of the .wall panel and its upper portion projecting upwardly therebeyond. The T-rail 95 is used around the entire periphery of the wall structure. In order to insure air tightness in the chamber, prior to assembling the T-rails to the upper edge of the panel. a suitable sealant, such as caulking 98 (FIG, 8) is deposited over the upper ends of the U-clips 65 and the associated flanges and lips confronting the interior of the drying chamber. ln addition, as indicated'at 99, a bead of sealant may be laid along the upper edge of the body portion of the inner facing element to effect a seal between the lower portion of the cross piece 97 and the facing element.

As shown in FIG. 4, the fixed roof panels are mounted on the T-rails 95 by engaging the upwardly projecting portion of the cross bar 97 into the slots formed by the flanges and lips of the roof panel. In tho-se installations where the roof panels are not supported on all sides by the side wal-ls of the chamber, support beams are mounted to span between the side walls and underlie the otherwise unsupported edges of the roof panels. As shown in FIG. 14, the support beams may take the for'm of a channel beam 103 which is secured to rails 95 supported on the opposite sides of the chamber, for example by welding as indicated at 104. The beam` 103 may have a wear plate 105 extending along its upper surface. The beam underlies the free edge of the roo-f panel so as to support the same. If the adjoining roof panel is a fixed panel, the two panels are clipped together by U-shaped clip-s in a manner similar to the jointure of adjoining side panels, the supporting beam underlying t'he joint -between the panels, as shown in FIG. 15. lf the adjoining panel is an explosion panel, the junction shown in FIG. 13 is used, as described hereinafter.

The explosion panel 50b is mounted so as to be free for upward displacement in the event of explosion or coniiagarat-io-n within the chamber.

In the area Where the joint between the fixed panel 50a and the explosion panel 50h extends across the chamber intermediate the side walls as shown in FIG. 13, the explosion panel 50h is supported on a support strip 110 which is carried within the slot of the fixed panel 50a; To insure against inadverent displacement of the support member 110, the member is fastened Within the slot as indicated at 111. To provide a seal against the escape of gaseous mediumfrom the chamber, a U-shaped clip 65 may be enga-ged in the slots of the panels 50a and 50b to maintain these panels in proper engagement. The clip 65 does not exert sufficient resistance to separation of the panels in a vertical direction to retard an explosioncaused displacement of the explosion panel 50b. At the joint between adjacent explosion panels 50b, the panels are clipped together and supported by the beamA 103 in the same manner as shown in FIG. 15.

Where it is desired to mount an explosion panel on the side wall, an L-shaped support strip is mounted on the T-rail 95. To this end, as shown in FIG. 12, the explosion panel 50b, which is identical in construction to the panels 50h, rests upon the L-shaped support strip 109, one leg of which is provided with a reversely-turned lip to define a slot which is engaged upon the upwardly p-rojecting portion of the cross bar 97 of the rail 9S about the side walls of the chamber. In this way, the panel 50b is free for vertical displacement.

About the periphery of the chamber at the junction between the side walls and the roof, a filler strip is secured to the upper edges of the side panel members. As shown in the drawings, the filler strip 115 may comprise a block of insulation 116 having a facing sheet 117 mounted thereon. At the junction of the side walls with a fixed roof panel, as shown in FIG. 4, the facing sheet 117 may be secured directly to the side panel and the roof panel. In a location where an explosion panel 50b' is provided, the Ifacing sheet 117 is modified so as to be secured solely to the side panel, as shown in FIG. 12. At locations where machinery or other equipment is to be mounted on the top of the dryer chamber, the filler strip 115 may be replaced by a similar strip having structural reinforcing elements incorporated therein to provide additional structural support upon which the machinery or other equipment may be mounted. In such cases, since the pane-l members making up the side walls have suicient compressive strength in a vertical direction to support the normal equipment without buckling or otherwise failing, the structural reinforcement within the filler strip is desirable only to provide an effective distribution o-f the load of the equipment over a number of the side panels and to provide a tir-m support to which the equipment may be secured.

From the foregoing, it is apparent that the present invention provides a self-supporting structural assembly for use as a housing which is designed to be air-tight so that it may serve as a treating charnber which uses a gaseous medium without the need for interior ducts or distribution boxes. The panel assembly of the present invention is easily installed and disassembled, and enables the use of panel members having standard dimensions so as to afford ready replacement of panel sections. The construction of the panel members affords simple connection thereto of trim strips and the like by frictional engagement of the clips and rail members into slots provided by the construction of the flanges and llips thereof. The manner interconnection of the panel members by the engagement of U-shaped clips into tlhe slots formed by their flanges and lips affords a limited degree of thermal expansion and contraction, avoiding the necessity for providing expensive and complicated expansion joints. The panel assembly of the present invention also affords effective explosion-relief means without substantial increase in the cost of material or labor in erecting the assembly.

While a particular embodiment of the present invention has been herein illustrated and described, it is not intended to limit the invention to such disclosure, but changes and modifications may be made therein and thereto within the scope of the following claims.

I claim:

1. In an assembly of insulated panel members having parallel inner and outer facing elements on opposite sides of the center plane thereof, and spacer elements maintaining the same in spaced relation to receive insulating material therebetween, and connector means interconnecting said panel members in edge-to-edge alignment; the improvement wherein the panel members are .formed with side edges cooperable with said connector means, the edge formation comprising an inturned continuous ange on each facing element projecting toward and aligned with the inturned iiange on the opposed facing element, each of said flanges terminating short of the center plane of said panel member in an outer reverselyturned resilient lip biased towards a position converging outwardly toward said iiange and cooperating therewith to define a slot extending along the edge of said panel member, the slots of adjoining interconnected panel -members being disposed parallel to each other with the lips confronting each other, said connector means comprising a clip of U-shaped cross section coextensive in length with the line of juncture between said panel members, the legs of the U-shaped clip engaging respectively in the slots of the adjoining panel members and embracing the lips to firmly grip the legs of the clip therebetween, provide a labyrinth seal against the passage of gaseous medium through said juncture and effect the interconnection.

2. An assembly according to claim 1 wherein the legs of the U-shaped clip are shorter than the depth of the ange so that the clip does not project beyond the associated facing element, the spacing between the legs corresponding to the thicknesses of the lips received therebetween to provide a firm frictional engagement.

3. An assembly according to claim 2 including an anchoring sill member coextensive in length with and underlying said aligned panel members, said sill member comprising a U-shaped channel member having a pair of upstanding legs which are spaced apart a distance corresponding to the thickness of said panel members, said legs receiving the lower marginal portion of said assembled panel members therebetween.

4. An assembly according to claim 2 having roof panel members including a roof-supporting rail coextensve in length with said aligned side panel members, said side panel members having a top edge formation identical to said side edge formation, said rail having a T-shaped cross section with a horizontal leg and a vertical cross bar, the leg being engaged in the slot of said top edge formation, said cross bar having a portion below said leg bearing against the facing element of said side panel members and a portion above the leg projecting upwardly to support said roof panel members.

5. An assembly according to claim 4 wherein said roof panel members have edge formations identical to said side panel edge formations, the slot of said roof panel edge formation receiving said upwardly projecting portion of the cross bar.

6. An assembly according to claim 4 wherein said roof panel is supported so as to permit vertical displacement thereof to constitute said panel an explosion panel, said assembly including an L-shaped support strip, one leg of which has a reversely-turned lip defining a slot which is engaged upon the upwardly projecting portion of said rail, the other leg of which supports said explosion roof panel for vertical displacement.

7. An assembly according to claim 1 wherein the panel member assembly includes a pair of panel members in spaced-apart alignment to define therebetween a door opening, and a door panel mounted in said opening for swinging movement; said door panel comprising opposed parallel inner and outer facing elements operable when the door is closed to align with the inner and outer facing ele-ments of said panel members, said facing elements of the door panel having inturned peripheral walls projecting toward the center plane of said door panel and connected to each other by an insulating spacer member, the wall of said inner element being continuous and inset from` the wall of said outer element to provide a space surrounding said door `about its inner periphery, said door panel including a continuous flange on said inset wall projecting into said space, hinge means connected to said outer facing elements of the door panel and the panel member at the hinged side of said door opening, and continuous sealing means mounted on the inner facing elements of the panel members and projecting into said space to cooperate with said flange of the inset wall to seal the door opening when said door is closed with the inner and outer facing elements of the door panel and `panel members respectively aligned.

8. An assembly according to claim 7 wherein said hinge means comprises a piano hinge having one leaf secured to said door panel and its other leaf anchored in the slot formed by the flange and lip of the outer facing element of the panel member.

9. An assembly according to claim 7 including a door stop mounted on said panel members and projecting into said opening within the space provided by said inset wall,V

and a latch operable to retain said door panel engaged against said stop.

10. An assembly according to claim 7 wherein said sealing members are oriented in said space so as to effect engagement in a direction parallel to the center plane of the door on the hinged edge of the opening, and perpendicular to the center plane on the remaining edges 0f t the opening.

References Cited UNITED STATES PATENTS 1,604,079 10/1926 Schwartz 52-584 X 2,300,743 11/"1942 Hauf et al. 52-584 X 2,691,432 10/1954 Klein et al. 52-584 2,822,898 2/ 1958 Richards 52--471 2,927,665 3/1960 Hauf 52-584 X FOREIGN PATENTS 1,371,251 7/1964 France.

KENNETH DOWNEY, Primary Examiner. 

